CCR Operator

Purpose/Objective

Own end-to-end performance of the kiln section—delivering planned clinker output with stable quality (free lime, LSF/SM/AM), energy efficiency (specific heat), and emissions compliance—while ensuring zero harm. Govern CCR discipline, heatup/shutdown protocols, combustion/air–fuel balance, preheater and cooler stability, and cross-functional alignment with Quality, Mechanical, E&I, and Automation.

Key Responsibilities of Role

Production & Process Stability- Deliver daily/weekly clinker tonnage per plan; maintain steady burning zone temperature (BZT), flame shape, and draft/pressure profiles. - Govern CCR operations: setpoint windows, interlock adherence, alarm rationalization, trip recovery SOPs. B) Quality Assurance- Achieve clinker chemistry targets (LSF/SM/AM) and free lime within limits through controlled burning and coating stability. - Coordinate feed adjustments and corrective actions with QC/Process based on trends and test results. C) Energy & Emissions- Meet specific heat (kcal/kg clinker) targets via false-air reduction, optimized secondary/tertiary air, and APC usage. - Keep CO/NOx/PM within statutory limits; ensure baghouse DP stability and leak elimination with Maintenance. D) Shutdowns & Start-ups- Own heatup/shutdown/trip recovery SOPs, soak times, and controlled rampup post maintenance or refractory work. - Align shutdown scopes and startup readiness with Maintenance and Automation; drive startup success rate. E) EHS & Risk Management- Enforce PTW/LOTO, confined space, hot work, working at height; lead toolbox talks and JSAs for kiln interventions. - Maintain housekeeping standards and audit readiness in kiln/preheater/cooler areas. F) People Leadership & Capability- Build a skills matrix; coach CCR/field operators in stability cues, alarm discipline, upset playbooks, and trial protocols. - Conduct shift audits, performance reviews; recognize and correct behaviors. G) Reporting & Governance- Publish daily/weekly dashboards (throughput, quality, energy, alarms, downtime pareto). - Ensure data integrity in historian/LIMS/ERP; document trials, RCAs, and CAPA actions.

Technical Competencies

Kiln Operation & Control,Clinker Quality & Chemistry,Preheater/Calciner Management,Startup/Shutdown Protocols

Qualifications and Experience

- Education: BE/B.Tech in Chemical/Ceramics/Mechanical (process focus preferred). - Experience: 8–12+ years in kiln operations with 3–5+ years leading a kiln section/team. - Preferred Exposure: Rotary kiln with multistage preheater/calciner, grate cooler, DCS/APC platform, AFR coprocessing.